Injection Molding Designguide 0914 PDF

Injection Molding
Design Guide
Design Considerations for Rapid Manufacturing of
Plastic Parts Using Injection Molding
Injection Molding Design Guide
Table of Contents
1
Injection Mold Tooling Process Comparison 3
Size Considerations 4
Considerations for Undercuts
Other Generic Considerations 6
Parting Line Limitations . . . . . . . . . . . . . . . . . 6

Deep Ribs . . . . . . . . . . . . . . . . . . . . . . . 6
Rounded Corners. . . . . . . . . . . . . . . . . . . . 6
Sharp Corners. . . . . . . . . . . . . . . . . . . . . . 7
Rib-to-Wall thickness Rations . . . . . . . . . . . . . . 7
Warp . . . . . . . . . . . . . . . . . . . . . . . . . 7
Sufficient Draft . . . . . . . . . . . . . . . . . . . . . 7
5
Gating 8
Resin Selection 8
Surface Finish Section 10

Texturing. . . . . . . . . . . . . . . . . . . . . . . . 10
Polishing. . . . . . . . . . . . . . . . . . . . . . . . 10
Lead Time 11
Page 2
Injection Mold Tooling

Process Comparison
Rapid
Injection Molding
Low-Volume
Injection Molding
Production
Injection Molding
20 x 20 x 3
36 x 36 x 15
36 x 36 x 15
No undercuts causing slide action

in tooling; straight pull design
Standard Injection-Molding
Process Limitations
Standard Injection-Molding
Process Limitations
Part Material
Over 30 standard materials in stock

including ABS, PC, PP, PE, Nylon 6/6,
Acetal & Acrylic
Any commercially
available material
Any commercially
available material
Part Volume
36 in.3
No volume limit
No volume limit
No limit
No limit
No limit
Draft required in CAD model
Tolerance Expectations
+/- 0.005, or per SPE standards

for material
Tighter tolerances
are possible
Tighter tolerances
are possible
Surface Finish
Choose from 6 standard finishes
Any finish,
including acid-etched finish
Any finish,
including acid-etched finish
No
Yes
Yes
CNC-only manufacturing,
aluminum-only
No manufacturing limits,
aluminum and soft steels
No manufacturing limits,
tooling per customer specs
Standard: 10 Days for 10x10x3,

20 Days for 20x20x3
Expedited: 5 days,
depending upon your geometry
Standard: 15-20 Days

Expedited: 10 days,
depending upon your geometry
Standard: 4-6 Weeks
Part Size Limitation
Part Geometry Limitation
Parting Line Geometry
Draft
Customer Owns Tool?
Method of Tool Manufacture
Lead Time
Page 3
Size Considerations
Size Limits for Rapid Injection Molding

The XY dimensions must be less than 20 x 20.
Maximum part volume cannot exceed 36 cubic inches.
Maximum part depth can be 3, given a parting line that
can pass through the middle of the part, or 1.5 if the
parting line of the tool must be at one edge of the part.
Parts that fall outside of this box can be manufactured,
but must be quoted offline by your Quickparts tooling
manager.
Size Limits for Rapid Injection Molding is 20 x 20 x 3
The Depth Limit is 1.5 for parts where the parting line is on
the edge of the part, and 3 for parts where the parting line is
central to the part.
Size Limits for Low-Volume

Injection Molding
Size Limits for Production

Injection Molding
No volume limit.
No volume limit.
Page 4
Considerations for
Undercuts
Undercut Limits for Rapid Injection Molding

Parts that qualify for Rapid Injection Molding must be
designed as straight-pull parts.
A part made with a straight-pull mold is designed such that
when the two halves of the mold pull straight away from each
other, there is no mold metal that wants to pass through the
part plastic (an impossible, die locked situation).
Undercuts on the part require mold pieces to pull out
sideways, perpendicular to the direction of pull. These are
called side actions. Parts with undercuts are not available
within the Rapid Injection Molding process.
Undercut Limits for Low-Volume

Injection Molding
Undercut Limits for Production

Injection Molding
Undercuts are okay.
Undercuts are okay.
Page 5
Other Geometric Considerations
Parting Line Limitations
Rounded Corners
Rapid Injection Molding, Low-Volume Injection Molding and

Production Injection Molding all have no limitations on the
simplicity or complexity of a parts parting line.
Since Rapid Injection Molding is a CNC-only process, sharp

corners on the outside of parts (meaning sharp corners on the
inside of the cavity side of the tool) are not possible.
All 3 processes can support simple, complex, and contoured

parting lines.
The following illustrations show a part with sharp corners and

a part with rounded corners. If your design has sharp outside
corners, the CNC-only process will round off those features to a
radius of .030.
Deep Ribs
The Rapid Injection Molding process uses only high-speed
CNC machining centers to mill out the tooling material.
No special manufacturing methods, such as EDM (electric
discharge machining), wire EDM or grinding, are used to
manufacture the tools.
As a result of the CNC-only approach, deep ribs must be
designed to accommodate this limitation.
Specifically, deep ribs require proper draft (at least 2 degrees
per side) and clearance to allow the CNC machine tool to cut
the root of the rib cavity.
Rule of Thumb: The maximum rib depth is 10 times the width
of the rib at its smallest width. CNC cutting tool lengths (and
therefore rib depths) are limited by this.
Square Corners
- External square corners
impossible to CNC
- Inhibits the flow of plastic,
causing stress risers
Rounded Corners
- External square corners
impossible to CNC
- Inhibits the flow of plastic,
causing stress risers
It is strongly advised that you ensure your design has rounded

corners on every rib-to-wall or wall-to-wall intersection. This
design consistency will result in a part with less internal stress
reducing the chance of warp, short shots, splay and flash
regardless of which injection-molding process you use.
The following chart provides a rule of thumb for rib depth with
1 degree per side of draft:
Rib Depth 0.5mm
0.75mm 1.0mm
1.5mm
2.0mm
Rib Width
7.5mm
25mm
36mm
3.5mm
15mm
Low-Volume Injection Molding and Production Injection

Molding have no restrictions on rib depth.
Page 6
Sharp Corners
Warp
If your design requirements are so stringent that sharp corners

on the outside of your part are critical to the parts function,
only Low-Volume Injection Molding or Production Injection
Molding will meet that need.
The flow of plastic in a tool is a complex phenomenon

sometimes friendly and predictable, other times evil and erratic.
Low-Volume Injection Molding and Production Injection Molding

can accomplish the cavity-side sharp corner using EDM machining
methods to literally burn the sharp corner into the tool.
Rib-to-Wall Thickness Ratios

Thin ribs on thicker walls may provide stiffness, but they can
also result in sink marks, which can be unsightly and cause
tolerance problems.
Rule of thumb: Rib root thickness should equal 0.6 x Wall
Thickness to prevent sink.
After the molten plastic has filled the tool cavity, the plastic
solidifies in the mold and freezes in a direction from the outside
of the part (near the mold surface) toward the inside.
In thick sections of the part, this results in inward pulling
stresses (due to the contraction of cooling), causing sink marks
in the outer surfaces of the part.
Because thinner areas of the part will freeze faster than thicker
sections, stresses can build up between thick and thin sections.
The result is a phenomenon called warp.
Rule of thumb to minimize warp: Design your parts to maintain
consistent wall thickness and avoid thick areas whenever possible.
Sufficient Draft
The existence of draft on vertical surfaces of your part enables
the easy removal of your part from the mold.
Draft is especially important in Rapid Injection Molding since
the molds are straight-pull only (i.e., no side actions) and
manufactured using a CNC-only process.
The rules of thumb governing the amount of draft required
(in degrees) will vary with geometry and surface texture
requirements. Lets put it this way the more draft, the better.
In some cases, using a glass-filled material will help avoid sink in
geometries when adhering to the rule of thumb is impossible.
Rules of thumb for draft:

Use at least 1 degree on all vertical faces.
2 degrees works very well in most situations.
3 degrees is a minimum for a shutoff (metal sliding on metal).
3 degrees is required for light and medium texture.
Page 7
Gating
Rapid Injection Molding tooling is created with one of the

following types of gates:
Edge Gate
Tab Gate
Center Gate
Sub Gate
Gate vestige will be trimmed to +/-.005.
Low-Volume Injection Molding and Production Injection
Molding have no restrictions on the type of gate used.
Resin Selection
Selection of the proper material for your molded parts is a

critical decision.
One must consider the mechanical properties, molding
properties and cost of the resin they select for the given
application. Application-specific requirements will always drive
the need for particular material properties, like tensile strength
and elasticity.
Successful plastic part design is based on an understanding

of process-related issues during manufacturing, such as mold
filling, likelihood of flash, part ejection and the potential for
warp and sink.
The table below lists some commonly used resins, along with
their brand names, and a high-level summary of their material
properties, moldability characteristics and relative costs.
Page 8
Standard Rapid Injection Molding Resins

Strength
Impact
Resistance
Change to
Stiffness
Delrin
Medium
Medium
36 x 36 x 15
Nylon 6/6
Zytel
Medium
High
No geometry limits
Nylon 6/6, glass filled
Zytel
High
Medium
Any commercially
available material
Polypropylene (PP)
Marlex, Sumika
Low
High
No volume limit
Polycarbonate (PC)
Lexan
Medium
High
No limit
Resin Generic Names
Resin Brand Names
Acetal
Acrylonitrile Butadiene
Styrene (ABS)
Cycolac
Med-Low
High
Draft required in
CAD model
Polycarbonate / ABS Alloy
Cycoloy
Medium
High
Tighter tolerances
are possible
Polyetherimide (PEI)
Ultem
High
Medium
Any finish, including

acid-etched finish
Polyetherimide,
fiber reinforced (PEI)
Ultem
Very High
Medium
Yes
Polybutylene
Terephthalate (PBT)
Valox
Medium
High
No manufacturing
limits, tooling per
customer specs
Polystyrene
Styron
Med-Low
Low
Standard: 4-6 Weeks
Thermoplastic Elastomer
Thermoplastic Polyurethane,
Santoprene
Low
High
Notes: This list is not comprehensive, nor is it constant. There are many other resins not listed here. Ask your Quickparts tooling
manager for material selections that are currently available.
In order to avoid project delays due to material availability, we limit material selection in Rapid Injection Molding to the material
we have on hand at the time your quote is created. Your quote worksheet will present you with the currently available materials.
When your project requires a specific engineered material, it becomes either a Low-Volume Injection Molding or Production
Injection Molding project. Virtually any injection moldable material can be specified, as we will source the material per
your requirements.
Page 9
Surface Finish Section
When designing a part for injection molding, it is important

to keep in mind the relationships between surface finish,
moldability, cost and lead time.
Rapid Injection Molding offers the following standard surface
finishes, listed in order from lowest to highest cost:
Non-cosmetic: Finish to Rapid Injection Molding

discretion
SPI-C3: 320 Stone finish
SPI-B3: 320 Grit Paper
SPI-A3: Grade #15 Diamond Buff (+2 days extra on lead
time)
Light matte texture, MoldTech 11010 Equiv. (+2 days on
lead time)
Medium matte texture, MoldTech 11060 (+2 days extra on
lead time)
** SPI (The Society of the Plastics Industry) denotes
an industry-standard finish.
If the part will not be visible to the end user, a non-cosmetic

finish is acceptable. But many times your design will require a
cosmetic surface finish.
In these cases of cosmetic finishes, there are two key
limitations to be aware of: Texturing and Polishing.
Texturing
Since bead blasting is a line-of-sight method, it may not be
possible to texture the sides of minimally drafted ribs on a
part, as the mold surfaces may be inaccessible.
Also, texturing has an adverse effect on the ability of the part
to release from the mold. Drag marks may result.
Therefore, we recommend that texture be specified only on
areas of the part that are drafted at least 3 degrees.
Polishing
We use manual mold polishing methods to apply the SPI-A3
finish.
Since there is not significant automation in this process, you
should expect a significant cost increase, as it is labor intensive
and time consuming to polish deep, narrow slots in molds.
Polishing is time intensive and may also affect the lead time for
your parts.
In both Low-Volume Injection Molding and Production
Injection Molding, any surface finish can be produced,
including acid-etched finish.
Page 10
Lead Time
Standard lead time for Injection Molding service is as follows:
Process
Standard Lead Time
Fastest Lead Time
Rapid Injection Molding
10 days for 10x 10x 3 parts

20 days for 20x 20x 3 parts
5 days, depending upon geometry
Low-Volume Injection Molding
15 20 days
10 days, depending upon geometry
Production Injection Molding
4-6 weeks
4 weeks
Lead times can change based on current factory load. Call your Quickparts Tooling Manager at 1.877.521.8683 to discuss your
specific lead time requirements.
3D Systems Corporation | Quickparts Solutions | 301 Perimeter Center North, Suite 400 | Atlanta, GA 30346 | USA
Toll Free: +1 877.521.8683 | Tel: +1 770.901.3200 | quote@quickparts.com | www.3dsystems.com/quickparts
Page 11

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What factors determine the size limits for rapid injection molding?

What factors determine the size limits for rapid injection molding?

What surface finish options are available for rapid injection molding and what are the tradeoffs?

What surface finish options are available for rapid injection molding and what are the tradeoffs?

Injection Molding

Injection Molding Design Guide

Injection Mold Tooling Process Comparison 3

Considerations for Undercuts

Other Generic Considerations 6

Parting Line Limitations . . . . . . . . . . . . . . . . . 6

Surface Finish Section 10

Injection Molding Design Guide

Injection Mold Tooling

No undercuts causing slide action

Over 30 standard materials in stock

Draft required in CAD model

Draft required in CAD model

Draft required in CAD model

+/- 0.005, or per SPE standards

Choose from 6 standard finishes

Standard: 10 Days for 10x10x3,

Standard: 15-20 Days

Standard: 4-6 Weeks

Part Size Limitation

Part Geometry Limitation

Parting Line Geometry

Customer Owns Tool?

Method of Tool Manufacture

Injection Molding Design Guide

Size Limits for Rapid Injection Molding

Size Limits for Low-Volume

Size Limits for Production

The XY dimensions must be less than 36 x 36.

The XY dimensions must be less than 36 x 36.

Injection Molding Design Guide

Undercut Limits for Rapid Injection Molding

Undercut Limits for Low-Volume

Undercut Limits for Production

Undercuts are okay.

Undercuts are okay.

Injection Molding Design Guide

Other Geometric Considerations

Parting Line Limitations

Rapid Injection Molding, Low-Volume Injection Molding and

Since Rapid Injection Molding is a CNC-only process, sharp

All 3 processes can support simple, complex, and contoured

The following illustrations show a part with sharp corners and

It is strongly advised that you ensure your design has rounded

Low-Volume Injection Molding and Production Injection

Injection Molding Design Guide

If your design requirements are so stringent that sharp corners

The flow of plastic in a tool is a complex phenomenon

Low-Volume Injection Molding and Production Injection Molding

Rib-to-Wall Thickness Ratios

Rules of thumb for draft:

Injection Molding Design Guide

Rapid Injection Molding tooling is created with one of the

Selection of the proper material for your molded parts is a

Successful plastic part design is based on an understanding